Edge-reinforced seamed belts

Abstract

Seamed belts, in particular puzzle-cut imageable seam intermediate transfer belts and electrophotographic printing machines that use such transfer belts, that are resistant to unzipping. The seamed belts include a first substrate having a first end and a second end that mate to form a first seam that runs across the first substrate. Along at least one side edge of each end of the first substrate is a cut-out. With the first end and the second end mated to form the first seam the cut-outs align to form a larger cut-out. A second substrate is then fitted into the larger cut-out along a second seam. Beneficially, an adhesive is disposed over the first seam and the second seam. Imageable seam intermediate transfer belts have first and second substrates that are beneficially semiconductive and puzzle-cut seams.

Description

FIELD OF THE INVENTION

This invention relates to seamed belts.

BACKGROUND OF THE INVENTION

Electrophotographic printing is a well-known and commonly used method of copying or printing documents. Electrophotographic printing is performed by exposing a light image representation of a desired document onto a substantially uniformly charged photoreceptor. In response to that light image the photoreceptor discharges, creating an electrostatic latent image of the desired document on the photoreceptor's surface. Toner is then deposited onto that latent image, forming a toner image. The toner image is then transferred from the photoreceptor onto a receiving substrate such as a sheet of paper. The transferred toner image is then fused with the substrate, usually using heat and/or pressure. The surface of the photoreceptor is then cleaned of residual developing material and recharged in preparation for the production of another image.

The foregoing generally describes black and white electrophotographic printing machines. Electrophotographic printing can also produce color images by repeating the above process for each color of toner that is used to make the color image. For example, the photoreceptive surface may be exposed to a light image that represents a first color, say black. The resultant electrostatic latent image can then be developed with black toner particles to produce a black toner layer that is subsequently transferred onto a receiving substrate. The process can then be repeated for a second color, say yellow, then for a third color, say magenta, and finally for a fourth color, say cyan. When the toner layers are placed in superimposed registration the desired composite color toner image is formed and fused on the receiving substrate.

The color printing process described above superimposes the color toner layers directly onto a substrate, such as paper. Other electrophotographic printing systems use intermediate transfer belts. In such systems successive toner layers are electrostatically transferred in superimposed registration from the photoreceptor onto an intermediate transfer belt. Only after the composite toner image is formed on the intermediate transfer belt is that image transferred and fused onto the substrate. Indeed, some electrophotographic printing systems use multiple intermediate transfer belts, transferring toner to and from belts as required to fulfill the requirements of the machine's overall architecture.

In operation, an intermediate transfer belt is brought into contact with a toner image-bearing member such as a photoreceptor belt. In the contact zone an electrostatic field generating device such as a corotron, a bias transfer roller, a bias blade, or the like creates electrostatic fields that transfer toner onto the intermediate transfer belt. Subsequently, the intermediate transfer belt is brought into contact with a receiver. A similar electrostatic field generating devices then transfers toner from the intermediate transfer belt to the receiver. Depending on the system, a receiver can be another intermediate transfer member or a substrate onto which the toner will eventually be fixed. In either case the control of the electrostatic fields in and near the transfer zone is a significant factor in toner transfer.

Intermediate transfer belts often take the form of seamed belts fabricated by fastening two ends of a web material together, such as by welding, sewing, wiring, stapling, or gluing. While seamless intermediate transfer belts are possible, they require manufacturing processes that make them much more expensive than similar seamed intermediate transfer belts. This is particularly true when the intermediate transfer belt is long. While seamed intermediate transfer belts are relatively low in cost, the seam introduces a discontinuity that interferes with the electrical, thermal, and mechanical properties of the belt. While it is possible to synchronize a printer's operation with the motion of the intermediate transfer belt such that toner is not electrostatically transferred onto the seam, such synchronization adds to the printer's expense and complexity, resulting in loss of productivity. Additionally, since high speed electrophotographic printers typically produce images on paper sheets that are cut from a continuous paper “web,” if the seam is avoided the resulting unused portion of the paper web must be cut-out, producing waste. Furthermore, even with synchronization the mechanical problems related to the discontinuity, such as excessive cleaner wear and mechanical vibrations, still exist. However, because of the numerous difficulties with transferring toner onto and off of a seamed intermediate transfer belt, in the prior art it was necessary to avoid toner transfer onto (and thus off of) a seam.

Acceptable intermediate transfer belts require sufficient seam strength to achieve a desired operating life. While that life depends on the specific application, typically it will be at least 100,000 operating cycles, but more preferably 1,000,000 cycles. Considering that a seamed intermediate transfer belt suffers mechanical stresses from belt tension, traveling over rollers, moving through transfer nips, and passing through cleaning systems, achieving such a long operating life is not trivial. Thus the conflicting constraints of long life and limited topographical size at the seam places a premium on adhesive strength and good seam construction.

A prior art “puzzle-cut” approach to seamed belts significantly improves the seam's mechanical strength. U.S. Pat. No. 5,514,436, issued May 7, 1996, entitled “Puzzle Cut Seamed Belt;” U.S. Pat. No. 5,549,193 entitled “Endless Seamed Belt with Low Thickness Differential Between the Seam and the Rest of the Belt;” and U.S. Pat. No. 5,487,707, issued Jan. 30, 1996, entitled “Puzzle Cut Seamed Belt With Bonding Between Adjacent Surface By UV Cured Adhesive” teach the puzzle-cut approach. While the puzzle-cuts described in the forgoing patents improve a seam's strength, further improvements would be beneficial. In particular, puzzle-cut seamed belts are susceptible to unzipping. That is, forces across an end of a seam can cause the end puzzle-cut interlock to separate. Additional forces then cause the next puzzle-cut interlock to fail, and so on as the puzzle-cut seam unzips.

For a seamed intermediate belt to be acceptable, the final image produced from across the seam must be comparable in quality to images formed across the remainder of the belt. This is a difficult task due to a number of interrelated factors. Some of those factors relate to the fact that the seam should not greatly impact the electrostatic fields used to transfer toner. However, electrostatic transfer fields are themselves dependent on the electrical properties of the intermediate transfer belt. While this dependency is complex, briefly there are conditions where transfer fields are very sensitive to the resistivity and thickness of the materials used for the various layers of the intermediate transfer belt. Under other conditions the electrostatic transfer fields are relatively insensitive to those factors. Similarly, there are conditions where the electrostatic transfer fields are very sensitive to the dielectric constants of the materials used for the layers of the intermediate transfer belt, and other conditions where the electrostatic transfer fields are insensitive to the dielectric constants. Therefore, to successfully transfer toner onto and off of a seamed intermediate transfer belt the electrical properties across and around the seam should be carefully controlled to produce a proper relationship with the remainder of the belt. Since the electrical properties depend on the interrelated factors of seam geometry, seam construction (such as adhesive beyond the seam), seam topology, seam thickness, the presence of an overcoating, and various other factors those factors should be taken into consideration for a given application.

From above it can be seen that a seam's topography is very important if one wants to transfer toner onto and off of a seam region without significant degradation of the final image. The seam topography includes not only the seam itself, but also any overflow of the adhesive used in the seam. This overflow can occur on both the toner-bearing side and the back-side of the belt. Adhesive overflow is important because the belt seam strength can depend upon on that overflow. However, excessive overflow increases various mechanical, electrical, and xerographic problems. Furthermore, the adhesive's electrical properties are a concern.

More information regarding imageable seam intermediate transfer belts can be found in U.S. Ser. No. 09/460,896, U.S. Pat. No. 6,245,402, entitled “Imageable Seam Intermediate Transfer Belt Having An Overcoat,” by Edward L. Schlueter, Jr. et al., and U.S. Ser. No. 09/460,821, U.S. Pat. No. 6,261,659, entitled “Imageable Seam Intermediate Transfer Belt,” by Gerald M. Fletcher et al., both filed on Dec. 14, 1999. Those patent documents discuss, among other things, “short-wavelength” and “long-wavelength” spatial disturbances, conformable overcoats, Paschen air breakdown, transfer nip air gaps, suitable electrical properties, material layers, material compositions, environmental and aging concerns, cleaning, surface friction, and “set point control” approaches to enable wider tolerances in electrical properties.

The present invention specifically relates to improving a seam's mechanical properties without significantly degrading the other desirable properties of the belt, particularly when that belt is an imageable seam intermediate transfer belt. As previously indicated, prior art puzzle-cut seams have a tendency to unzip. Therefore, a seamed belt with improved resistance to unzipping would be beneficial. Even more beneficial would be a puzzle-cut belt that is resistant to unzipping. Even more beneficial would be a puzzle-cut, imageable seam intermediate transfer belt that is resistant to unzipping.

SUMMARY OF THE INVENTION

The principles of the present invention provide for seamed belts that are resistant to unzipping, in particular, puzzle-cut imageable seam intermediate transfer belts that find use in marking machines. A seamed belt according to the present invention includes a first substrate having a first end and a second end that mate to form a first seam that runs across the substrate. Along at least one side edge of each end of the first substrate is a cut-out. With the first end and the second end mated to form the first seam the cut-outs align to form a larger cut-out such that the first seam begins at the larger cut-out. A second substrate is then fitted into the larger cut-out along a second seam. Beneficially, an adhesive is disposed over the first seam and the second seam. If the seamed belt is an imageable seam intermediate transfer belt the first and second substrates are beneficially semiconductive and the seams are beneficially puzzle-cut. Furthermore, it may be beneficial to include cut-outs on each side edge of each end of the first substrate such that forming the first seam produces two larger cut-outs, one on each side of the first substrate, with the first seam running between the two larger cut-outs. Then, a second substrate is fitted into one of the larger cut-outs along a second seam and a third substrate is fitted into the other larger cut-out along a third seam. If the seamed belt is an imageable seam intermediate transfer belt the substrates are all beneficially semiconductive and all of the seams are beneficially puzzle-cut. Preferably, imageable seam intermediate transfer belts according to the principles of the present invention find use in electrophotographic printing machines.

BRIEF DESCRIPTION OF THE DRAWINGS

Other features of the present invention will become apparent as the following description proceeds and upon reference to the drawings, in which:

FIG. 1 is an isometric representation of a puzzle-cut seamed intermediate transfer belt that is in accord with the principles of the present invention;

FIG. 2 is a close-up, top down view of puzzle-cut tabs as used in the belt of FIG. 1;

FIG. 3 shows puzzle-cut tabs shown in FIG. 2 interlocked with a matching edge to form a kerf;

FIG. 4 shows the puzzle-cut tab of FIG. 3 with the kerf filled with an adhesive;

FIG. 5 illustrates a close-up view of a seam mating area highlighted in FIG. 1;

FIG. 6 illustrates an electrophotographic printing machine that uses a seamed intermediate transfer belt that is in accord with the principles of the present invention; and

FIG. 7 illustrates a more detailed view of part of the electrophotographic printing machine illustrated in FIG. 6.

DETAILED DESCRIPTION OF THE INVENTION

While the principles of the present invention are described below in connection with an imageable seam intermediate transfer belt, and its application in an electrophotographic marking machine, it should be understood that the present invention is not limited to those embodiments. On the contrary, the present invention is intended to cover all alternatives, modifications, and equivalents as may be included within the spirit and scope of the appended claims.

An imageable seam intermediate transfer belt 8 that is in accord with the principles of the present invention is illustrated in FIG. 1. That belt includes a semiconductive substrate layer 10 that has its ends joined together to form a continuous belt using mechanically interlocked “puzzle-cut” tabs that form a seam 11. Furthermore, the imageable seam intermediate transfer belt 8 includes a second substrate 13 that mates to the remainder of the belt along a puzzle-cut seam 14 and a third substrate 15 that joins to the remainder of the belt along a puzzle-cut seam 16. Reference U.S. Pat. Nos. 5,487,707; 5,514,436; 5,549,193; and 5,721,032 for additional information on puzzle-cut patterns. Typically the seam 11 is about ¼ inch wide.

The imageable seam intermediate transfer belt 8 is thus formed from three substrates, the substrates 10, 13, and 15, with the substrates 10 and 13 joined by the seam 14 and the substrates 10 and 15 joined by the seam 16. The imageable seam intermediate transfer belt 8 is beneficially made by forming puzzle-cut patterns on each end of the substrate 10. Then, along each side edge of each end of the substrate 10 there is formed a cut-out having puzzle-cut edges. Then, the first end and the second end of the substrate 10 are mated to form a larger cut-out on each side of the belt. The substrate 13 having puzzle-cut tabs that mate with the puzzle-cut patterns on one side of the substrate is then placed in one cut-out while the substrate 15, having puzzle-cut tabs that mate with the puzzle-cut patterns on the other side of the substrate is then placed in its cut-out. An adhesive is then disposed over the seams 11, 14, and 16.

The substrates 10, 13, and 15 can be made from a number of different materials, including polyesters, polyurethanes, polyimides, polyvinyl chlorides, polyolefins (such as polyethylene and polypropylene) and/or polyamides (such as nylon), polycarbonates, or acrylics, or blends or aloys of such materials. Beneficially, all of the substrates are made from the same material. If required, the selected material is modified by the addition of an appropriate filler such that the substrate layer has a desired electrical conductivity. Appropriate fillers can include, for example, carbon, Accufluor® fluorinated carbon black, and/or polyanaline, polythiophene or other conductive fillers or polymers. Donor salts can also be used. The substrate layer material should have the physical characteristics appropriate to an intermediate transfer application, including good tensile strength (Young's modulus, typically 1×103 to 1×106 Newton's/m2, resistivity (typically less than 1013 ohm cm volume resistivity, greater than 108 ohms/square lateral resistivity), thermal conductivity, thermal stability, flex strength, and high temperature longevity. See the previously referenced U.S. patent applications Ser. No. 09/460,896, U.S. Pat. No. 6,245,402, entitled “Imageable Seam Intermediate Transfer Belt Having An Overcoat,” by Edward L. Schlueter, Jr. et al., and Ser. No. 09/460,821, U.S. Pat. No. 6,261,659, entitled “Imageable Seam Intermediate Transfer Belt,” by Gerald M. Fletcher et al., both filed on Dec. 14, 1999.

FIG. 2 shows a top view of a puzzle-cut tab pattern. That pattern is comprised of tabs that are comprised of a neck 18 and a node 20. The shape of the tabs defines female interlocking portions 22. The tabs on each end are dimensioned to interlock. The puzzle-cut tabs may be formed using any conventional shaping technique, such as die cutting, or cutting wheels, or laser cutting, specifically using a laser micro-machining system.

FIG. 3 shows a top view of the puzzle-cut tabs of FIG. 2 interlocked together. The shape of the interlocking tabs reduce stress concentrations along the seam (seam 11 shown in FIGS. 3 and 4) and permit easy travel around curved members, such as rollers 12 as shown in FIG. 1. Physically interlocking the puzzle-cut tabs may require pressure when mating. The interlocking tabs produce a gap between the mutually mating elements that is called a kerf 24. The gap arises because of the difference between the necks 18/nodes 20 and the female interlocking portions 22. As shown in FIG. 4 the interlocking tabs are held together using an adhesive 26 that fills the kerf. The adhesive is designed to be physically, chemically, thermally, mechanically, and electrically compatible with the substrate layer material(s). Seams with a 25 micron kerf have been typical for puzzle-cut seams, while a kerf less than about 5 microns is generally preferred. Significantly, the adhesive and the puzzle-cut tabs act together to create a strong seam. Ideally the seam should be strong, smooth, and mechanically uniform.

The adhesive 26 should have a viscosity such that it readily wicks into the kerf. Additionally, the surface energy of the adhesive should be compatible with the substrate layer material such that the adhesive adequately wets and spreads. Furthermore, the adhesive should remain flexible and should adhere well to the substrate layer material. Finally, the adhesive also should have low shrinkage during curing. As an example, the adhesive can be a hot melt adhesive that is heated and pressed into the seam such that the adhesive is flattened, making it as mechanically uniform as possible with the substrate layer 10. Alternatively, the adhesive can be an epoxy-like material, a UV curable adhesive including acrylic epoxies, polyvinyl butyrals, or the like. Further, the “adhesive” can be substantially the substrate material itself, either applied during a separate adhesive application step or else by melting the two ends sufficiently to cause adhesion of the mutually mating elements. Finally, the adhesives may be electrically modified as required for the particular application. Following the application of the adhesive the seam 11 can be finished by buffing, sanding, or micro polishing to achieve a smooth topography.

The relative electrical properties of the adhesive and the substrate materials are very important because they significantly affect the transfer characteristics of the resulting seam as compared to the transfer characteristics of the rest of the belt. Therefore, the adhesive should produce seams that have electrical properties that correspond to that of the substrate material(s). That is, under operating conditions a seam should create an electrostatic transfer field in the toner transfer zones that is within at least 20%, preferably within 10%, of the electrostatic transfer field that is present for the remainder of the belt. Ideally the seam electrical properties are substantially the same as the substrate material(s) and have substantially the same electrical property dependence as the substrates on all important factors, such environment, applied field, and aging. However, significant differences in electrical properties can be allowed for some imageable seam conditions as discussed subsequently. The adhesive electrical properties can be met by mixing fillers or additives with an adhesive. For example, an adhesive might contain silver, indium tin oxide, CuI, SnO2, TCNQ, Quinoline, carbon black, NiO and/or ionic complexes such as quaternary ammonium salts, metal oxides, graphite, or like conductive fillers and conductive polymers such as polyanaline and polythiophenes.

Compared to prior art puzzle-cut seamed intermediate transfer belts, a belt according to the present invention has improved resistance to unzipping. Referring now to FIG. 1, in the prior art, forces 26 and 28 along an edge of the belt previously tended to unzip the seam 11. However, the presence of the seam 14 and the substrate 13 significantly reduces this tendency. FIG. 5 shows a more detailed view of the relationship between the substrates 10 and 13 and the seams 11 and 14. As shown, the seam 11 connects to the seam 14 at a location 30. Forces 26 and 28 distribute across the seam 14. Of course, the other end of the seam 11 terminates similarly at the substrate 15 and the seam 16.

The imageable seam intermediate transfer belt 8 is beneficially formed by fashioning substrate 10 with puzzle-cut tabs along a first end and on a second end and with cut-outs on each side edge. Those cut-outs also include puzzle-cut tabs. The ends then interlock to form the seam 11 while the cut-outs on each side of the belt align to form a larger cut-out such that the seam 11 runs between the cut-outs on each side. The substrate 13, which has puzzle-cut tabs, is then fitted into one of the larger cut-outs, while the substrate 15 is fitted into the other larger cut-out. An adhesive is then disposed over the seams 11, 14, and 16. Beneficially the substrates 10, 13, and 15 are of the same material.

An electrophotographic marking machine 100 that makes beneficial use of the imageable seam intermediate transfer belt 8 is illustrated in FIGS. 6 and 7. With reference to those figures (primarily FIG. 6) the electrostatographic printer 100 includes the imageable seam intermediate transfer belt 8, which is driven over guide rollers 114, 116, 118, and 120. The imageable seam intermediate transfer belt 8 moves in a process direction shown by the arrow B. For purposes of discussion, the imageable seam intermediate transfer belt includes sections that will be referred to as toner areas. A toner area is that part of the intermediate transfer belt that receives actions from the various stations positioned around the imageable seam intermediate transfer belt. While the imageable seam intermediate transfer belt may have multiple toner areas each toner area is processed in the same way.

A toner area is moved past a set of four toner image stations 122, 124, 126, and 128. Each toner image station operates to place a unique color toner image on the toner image of the imageable seam intermediate transfer belt 8. Each toner image producing station operates in the same manner to form developed toner image for transfer to the imageable seam intermediate transfer belt.

While the image producing stations 122, 124, 126, 128 are described in terms of photoreceptive systems, they may also be ionographic systems or other marking systems that form developed toner images. Each toner image producing station 122, 124, 126, 128 has an image bearing member 130. The image bearing member 130 is a drum supporting a photoreceptor 121 (see FIG. 7).

Turn now to FIG. 7, which shows an exemplary toner image producing station. That image bearing station generically represents each of the toner image producing station 122, 124, 126, 128. As shown, the photoreceptor 121 is uniformly charged at a charging station 132. The charging station is of well-known construction, having charge generation devices such as corotrons or scorotrons for distribution of an even charge on the surface of the image bearing member. An exposure station 134 exposes the charged photoreceptor 121 in an image-wise fashion to form an electrostatic latent image on an image area. The image area is that part of the image bearing member which receives the various processes by the stations positioned around the image bearing member 130. The image bearing member may have multiple image areas; however, each image area is processed in the same way.

The exposure station 134 preferably has a laser emitting a modulated laser beam. The exposure station then raster scans the modulated laser beam onto the charged image area. The exposure station 134 can alternately employ LED arrays or other arrangements known in the art to generate a light image representation that is projected onto the image area of the photoreceptor 121. The exposure station 134 exposes a light image representation of one color component of a composite color image onto the image area to form a first electrostatic latent image. Each of the toner image producing stations 122, 124, 126, 128 will form an electrostatic latent image corresponding to a particular color component of a composite color image.

The exposed image area is then advanced to a development station 136. The developer station 136 has a developer corresponding to the color component of the composite color image. Typically, therefore, individual toner image producing stations 122, 124, 126, and 128 will individually develop the cyan, magenta, yellow, and black that make up a typical composite color image. Additional toner image producing stations can be provided for additional or alternate colors including highlight colors or other custom colors. Therefore, each of the toner image producing stations 122, 124, 126, 128 develops a component toner image for transfer to the toner area of the imageable seam intermediate transfer belt 8. The developer station 136 preferably develops the latent image with a charged dry toner powder to form the developed component toner image. The developer can employ a magnetic toner brush or other well-known development arrangements.

The image area having the component toner image then advances to the pretransfer station 138. The pretransfer station 138 preferably has a pretransfer charging device to charge the component toner image and to achieve some leveling of the surface voltage above the photoreceptor 121 to improve transfer of the component image from the image bearing member 130 to the imageable seamed intermediate transfer member 8. Alternatively the pretransfer station 138 can use a pretransfer light to level the surface voltage above the photoreceptor 121. Furthermore, this can be used in cooperation with a pretransfer charging device.

The image area then advances to a transfer nip 140 defined between the image bearing member 130 and the imageable seam intermediate transfer belt 8. The image bearing member 130 and imageable seam intermediate transfer belt are synchronized such that each has substantially the same linear velocity at the first transfer nip 140. The component toner image is then electrostatically transferred from the image bearing member 130 to the imageable seam intermediate transfer belt by use of a field generation station 142. The field generation station 142 is preferably a bias roller that is electrically biased to create sufficient electrostatic fields of a polarity opposite that of the component toner image to thereby transfer the component toner image to the imageable seam intermediate transfer belt. Alternatively the field generation station can be a corona device or other various types of field generation systems known in the art. A prenip transfer blade 144 mechanically biases the imageable seam intermediate transfer belt 8 against the image bearing member 130 for improved transfer of the component toner image.

After transfer of the component toner image, the image bearing member 130 then continues to move the image area past a preclean station 139. The preclean station employs a pre-clean corotron to condition the toner charge and the charge of the photoreceptor 121 to enable improved cleaning of the image area. The image area then further advances to a cleaning station 141. The cleaning station 141 removes the residual toner or debris from the image area. The cleaning station 141 preferably has blades to wipe the residual toner particles from the image area. Alternately the cleaning station 141 can employ an electrostatic brush cleaner or other well-know cleaning systems. The operation of the cleaning station 141 completes the toner image production for each of the toner image producing stations.

Turning back to FIG. 6, the individual toner image producing stations 122, 124, 126, and 128 each transfer their toner images onto the imageable seam intermediate transfer belt 8. A first component toner image is advanced onto the imageable seam intermediate transfer belt at the transfer nip of the image producing station 122. Prior to the toner area arriving at that transfer nip the toner area is uniformly charged by a conditioning station 146. This reduces the impact of any stray, low or oppositely charged toner that might result in back transfer of toner into the image producing station 122. Such a conditioning station is positioned before each transfer nip.

The toner images from the individual toner image producing stations 122, 124, 126, and 128 are transferred such that the images are registered. That is, each of the individual color component images are transferred onto the imageable seam intermediate transfer belt 8 such that the human eyes perceives a desired composite color image.

Turning now to both FIGS. 6 and 7, the imageable seam intermediate transfer belt 8 then transports the composite toner image to a pre-transfer charge conditioning station 152 that levels the charges at the toner area of the imageable seam intermediate transfer belt and prepares them for transfer to a transfuse member 150. The pre-transfer charge conditioning station 152 is preferably a scorotron. A second transfer nip 148 is defined between the imageable seam intermediate transfer belt 8 and the transfuse member 150. A field generation station 142 and a pre- transfer nip blade 144 engage the imageable seam intermediate transfer belt and perform similar functions as the field generation stations 142 and pre-transfer blades 144 adjacent the transfer nips 140. The composite toner image is then transferred electrostatically onto the transfuse member 150.

The transfer of the composite toner image at the second transfer nip 148 can be heat assisted if the temperature of the transfuse member 150 is maintained at a sufficiently high optimized level and the temperature of the imageable seam intermediate transfer belt 8 is maintained at a considerably lower optimized level prior to the second transfer nip 148. The mechanism for heat assisted transfer is thought to be softening of the composite toner image during the dwell time of contact of the toner in the second transfer nip 148. This composite toner softening results in increased adhesion of the composite toner image toward the transfuse member 150 at the interface between the composite toner image and the transfuse member. This also results in increased cohesion of the layered toner pile of the composite toner image. The temperature on the imageable seam intermediate transfer belt prior to the second transfer nip 148 needs to be sufficiently low to avoid too high a toner softening and too high a resultant adhesion of the toner to the imageable seam intermediate transfer belt. The temperature of the transfuse member should be considerably higher than the toner softening point prior to the second transfer nip to insure optimum heat assist in the second transfer nip 148. Further, the temperature of the imageable seam intermediate transfer belt 8 just prior to the second transfer nip 148 should be considerably lower than the temperature of the transfuse member 150 for optimum transfer in the second transfer nip 148.

Turning now to FIG. 7, the transfuse member 150 is guided in a cyclical path by guide rollers 174, 176, 178, 180. Guide rollers 174, 176 alone or together are preferably heated to heat the transfuse member 150. The imageable seam intermediate transfer belt 8 and transfuse member 150 are preferably synchronized to have the generally same velocity in the transfer nip 148. Additional heating of the transfuse member is provided by a heating station 182. The heating station 182 is preferably formed of infra-red lamps positioned internally to the path defined by the transfuse member 150. The transfuse member 150 and a pressure roller 184 form a third transfer nip 186.

A releasing agent applicator 188 applies a controlled quantity of a releasing material, such as a silicone oil to the surface of the transfuse member 150. The releasing agent serves to assist in release of the composite toner image from the transfuse member 150 in the third transfer nip 186.

The transfuse member 150 preferably has a top most layer formed of a material having a low surface energy, for example silicone elastomer, fluoroelastomers such as Viton™, polytetrafluoroethylene, perfluoralkane, and other fluorinated polymers. The transfuse member 150 will preferably have intermediate layers between the top most and back layers constructed of a Viton™ or silicone with carbon or other conductivity enhancing additives to achieve the desired electrical properties. The back layer is preferably a fabric modified to have the desired electrical properties. Alternatively the back layer can be a metal such as stainless steel.

A substrate 170 is then advanced toward the third transfer nip 186. The substrate 170 is transported and registered by a material feed and registration system into a substrate pre-heater 173. The substrate pre-heater 173 includes a transport belt that moves the substrate 170 over a heated platen. The heated substrate 170 is then directed into the third transfer nip 186.

At the third transfer nip the composite toner image is transferred and fused to the substrate 170 by heat and pressure to form a completed document 172. The document 172 is then directed into a sheet stacker or other well know document handing system (not shown).

A cooling station 166 cools the imageable seam intermediate transfer belt 8 after the second transfer nip 148. A cleaning station 154 engages the imageable seam intermediate transfer belt and removes oil, toner or debris that may be remain onto the imageable seam intermediate transfer belt. The cleaning station 154 is preferably a cleaning blade alone or in combination with an electrostatic brush cleaner, or a cleaning web.

While the foregoing is sufficient to understand the general operation of electrophotographic printing machines that use imageable seam intermediate transfer belts, practical systems are somewhat difficult to achieve. This is because imageable seam intermediate transfer belts that produce acceptable final images, such as the imageable seam intermediate transfer belt 8, are subject to numerous electrical and mechanical constraints, limitations, and design problems. More detailed discussions of those constraints, limitations, and design problems are found in U.S. Ser. No. 09/460,896, U.S. Pat. No. 6,245,402, entitled “Imageable Seam Intermediate Transfer Belt Having An Overcoat,” in U.S. Ser. No. 09/460,821, U.S. Pat No. 6,261,659, entitled “Imageable Seam Intermediate Transfer Belt,” both filed on Dec. 14, 1999, and in U.S. Ser. No. 09/634,307, entitled “Electrophotographic Marking Machine Having An Imageable Seam Intermediate Transfer Belt,” filed on Aug. 8, 2000.

While this invention has been described in conjunction with specific embodiments, it is evident that many alternatives, modifications, and variations will be apparent to those skilled in the art. Accordingly, it is intended to embrace all such alternatives, modifications and variations that fall within the spirit and broad scope of the appended claims.

Claims

1. A seamed belt, comprising:

a first substrate having a first end and a second end that mate to form a first seam that runs across said first substrate, said first substrate further including a cut-out along at least one side edge at each end of said first substrate, wherein said first end and said second end are mated to form said first seam, and wherein said cut-outs align to form a larger cut-out; and

a second substrate fitted into said larger cut-out to form a second seam.

2. A seamed belt according to claim 1, wherein an adhesive is disposed over said first seam and said second seam.

3. A seamed belt according to claim 1, wherein said first and second substrates are semiconductive.

4. A seamed belt according to claim 1, wherein said first end and said second end are puzzle-cut.

5. A seamed belt according to claim 1, wherein said second seam is puzzle-cut.

6. A seamed belt according to claim 1, wherein said first substrate further includes a cut-out along both side edges at each end of said first substrate, wherein said cut-outs on a first side mate to form a first larger cut-out, wherein said cut-outs on a second side mate to form a second larger cut-out, and further including a third substrate fitted into said second larger cut-out along a third seam.

7. A seamed belt according to claim 6, wherein said third seam is puzzle-cut.

8. An imageable seam intermediate transfer belt, comprising:

a first semiconductive substrate having a first end and a second end that mate to form a first seam that runs across said first semiconductive substrate, said first semiconductive substrate further including a cut-out along at least one side edge at each end of said first semiconductive substrate, wherein said first end and said second end are mated to form said first seam, and wherein said cut-outs align to form a larger cut-out; and

a second semiconductive substrate fitted into said larger cut-out to form a second seam.

9. An imageable seam intermediate transfer belt according to claim 8, wherein an adhesive is disposed over said first seam and said second seam.

10. An imageable seam intermediate transfer belt according to claim 8, wherein said first end and said second end are puzzle-cut.

11. An imageable seam intermediate transfer belt according to claim 8, wherein said second seam is puzzle-cut.

12. An imageable seam intermediate transfer belt according to claim 8, wherein said first semiconductive substrate includes a cut-out along both side edges at each end of said first semiconductive substrate, wherein said cut-outs on a first side mate to form a first larger cut-out, wherein said cut-outs on a second side mate to form a second larger cut-out, and further including a third semiconductive substrate fitted into said second larger cut-out along a third seam.

13. An imageable seam intermediate transfer belt according to claim 12, wherein said third seam is puzzle-cut.

14. A marking machine, comprising:

a moving photoreceptor belt;

a charging station for charging said photoreceptor belt;

an imaging station for exposing said charged photoreceptor belt so as to produce a latent image;

a developer for depositing toner on said latent image;

a transfer station for transferring said deposited toner onto a substrate, said transfer station including an intermediate transfer belt that receives toner from said charging station;

a fuser having a fusing member for receiving toner from said intermediate transfer belt and for fusing said transferred toner to said substrate; and

a cleaning station for cleaning said photoreceptor;

wherein said intermediate transfer belt comprises:

a first semiconductive substrate having a first end and a second end that mate to form a first seam that runs across said first semiconductive substrate, said first semiconductive substrate further including a cut-out along at least one side edge at each end of said first semiconductive substrate, wherein said first end and said second end are mated to form said first seam, and wherein said cut-outs align to form a larger cut-out; and

a second semiconductive substrate fitted into said larger cut-out to form a second seam.

15. A marking machine according to claim 14, wherein an adhesive is disposed over said first seam and said second seam.

16. A marking machine according to claim 14, wherein said first end and said second end are puzzle-cut.

17. A marking machine according to claim 14, wherein said second seam is puzzle-cut.

18. A marking machine according to claim 14, wherein said first semiconductive substrate includes a cut-out along both side edges at each end of said first semiconductive substrate, wherein said cut-outs on a first side mate to form a first larger cut-out, wherein said cut-outs on a second side mate to form a second larger cut-out, and further including a third semiconductive substrate fitted into said second larger cut-out along a third seam.

19. A marking machine according to claim 18, wherein said third seam is puzzle-cut.